Stator

Abstract

A stator (10) is composed of a plurality of stator constituent parts (12). Each of the stator constituent parts includes: a plurality of core constituent members (14) constituting an annular yoke (20) and having a yoke constituent part (22), which is divided in the circumferential direction of the yoke, and a teeth part (24), which protrudes inward from the yoke constituent part in the radial direction of the yoke; a winding (16) having a winding part (26) wound around the teeth part; and an insulator (18) having a plurality of insulation parts (30), which are attached to the core constituent members and insulate the teeth parts and the winding part, and a connection part (32), which connects the plurality of insulation parts to each other. The connection part has a holding part (38) which holds a terminal part (28) of the winding.

Description

Stator CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is based on and claims the benefit of priority from Japanese Patent Application No. 2024-047180, filed on March 22, 2024, the entire contents of which are incorporated herein by reference.

[0002] The technology of the present disclosure relates to a stator.

[0003] The following technology is known for so-called split-core type stators (see, for example, Japanese Patent Application Laid-Open No. 2021-35260). A split-core type stator is composed of multiple stator components. Each stator component includes multiple core component members, windings, and insulators. Each core component member forms an annular yoke and has yoke component members divided in the circumferential direction of the yoke and teeth portions protruding from the yoke component members radially inward of the yoke. The windings have winding portions wound around the teeth portions. The insulators have multiple insulating portions and connecting portions. Each insulating portion is attached to a core component member and insulates the teeth portions from the winding portions. The connecting portions connect the multiple insulating portions together.

[0004] As a result of detailed investigations by the inventors, the following problem was found: In the above-described stator, the holding portion that holds the terminal end of the winding is formed in the insulating portion, and therefore the holding portion is located in the space where the winding portion is wound, which may reduce the space factor of the winding portion.

[0005] The technique of the present disclosure provides a stator that can suppress a decrease in the space factor of the winding portion.

[0006] The stator according to the disclosed technology is composed of a plurality of stator components, each of which comprises a plurality of core components forming a ring-shaped yoke and having yoke components divided circumferentially around the yoke and teeth protruding radially inward from the yoke components; a winding having a winding portion wound around the teeth; and an insulator attached to the core component and having a plurality of insulating portions that insulate the teeth and the winding portions and connecting portions that connect the plurality of insulating portions together, the connecting portions having holding portions that hold terminal portions of the windings.

[0007] According to the technique of the present disclosure, a stator is provided that can suppress a decrease in the space factor of the winding portion.

[0008] FIG. 1 is a perspective view of a stator according to an embodiment of the disclosed technique. FIG. 2 is a perspective view showing a state in which a plurality of stator components are shifted in the axial direction. FIG. 3 is a perspective view of a U-phase stator component. FIG. 4 is a perspective view of a V-phase stator component. FIG. 5 is a perspective view of a W-phase stator component. FIG. 6 is an enlarged perspective view of a main portion of a stator. FIG. 7 is an enlarged plan view of a main portion of a stator component. FIG. 8 is an enlarged perspective view of a main portion of a stator component according to a first modified example. FIG. 9 is an enlarged perspective view of a main portion of a stator component according to a second modified example. FIG. 10 is an enlarged perspective view of a main portion of a stator component according to a third modified example. FIG. 11 is an enlarged perspective view of a main portion of a stator component according to a fourth modified example. FIG. 12 is an enlarged perspective view of a main portion of a stator component according to a fifth modified example.

[0009] An embodiment of the technology of the present disclosure will be described below.

[0010] 1 to 5 show the configuration of a stator 10 according to one embodiment of the technology of the present disclosure. The stator 10 according to this embodiment is a so-called split-core type stator. The basic configuration of a split-core type stator is described in Patent Document 1. The stator 10 is applied to an inner-rotor type brushless motor. That is, a rotor (not shown) is rotatably housed inside the stator 10, and the stator 10 and the rotor form a brushless motor.

[0011] The stator 10 is composed of a plurality of stator components 12. The stator 10 has U-phase, V-phase, and W-phase, and the number of the plurality of stator components 12 corresponds to the number of U-phase, V-phase, and W-phase. That is, the stator 10 includes a U-phase stator component 12 (12U), a V-phase stator component 12 (12V), and a W-phase stator component 12 (12W). The plurality of stator components 12 are integrated by being assembled together in the axial direction of the stator 10. Each stator component 12 includes a plurality of core components 14, a winding 16, and an insulator 18.

[0012] Each core component 14 forms a ring-shaped yoke 20 (see Figure 1) and has a yoke component portion 22 divided circumferentially around the yoke 20, and teeth portions 24 protruding radially inward from the yoke component portion 22.

[0013] The winding 16 has a plurality of winding portions 26 wound around each tooth portion 24, crossover wires (not shown) connecting the plurality of winding portions 26 together, and a terminal portion 28. In each drawing, the winding portions 26 are indicated by imaginary lines (two-dot chain lines). The terminal portion 28 is the terminal portion at the start or end of the winding of the winding 16. The terminal portion 28 is connected to, for example, a circuit board (not shown) provided in the brushless motor.

[0014] The insulator 18 has a plurality of insulating portions 30 and a connecting portion 32. Each insulating portion 30 is attached to the core component member 14 and insulates the tooth portion 24 from the winding portion 26. The connecting portion 32 connects the plurality of insulating portions 30 together. The portion of the insulator 18 other than the plurality of insulating portions 30 is the connecting portion 32.

[0015] The connecting portion 32 has an annular portion 34, a plurality of extending portions 36, and a retaining portion 38. The annular portion 34 is formed in a circular ring shape along the circumferential direction of the insulator 18. The extending portions 36 extend from the annular portion 34 toward the insulating portion 30 (i.e., radially outward from the connecting portion 32). The tip ends of the extending portions 36 are connected to the insulating portion 30.

[0016] FIG. 6 shows an enlarged view of a main portion of the stator 10. FIG. 7 shows an enlarged view of a main portion of the stator component 12. More specifically, one of the extending portions 36 formed on each insulator 18 has a radial extending portion 40, an axial extending portion 42, and an inclined portion 44. The radial extending portion 40 extends from the annular portion 34 radially outward (toward the arrow A1) of the coupling portion 32, and the axial extending portion 42 extends from a tip end of the radial extending portion 40 toward one axial side (toward the arrow B1) of the coupling portion 32. The inclined portion 44 extends from the annular portion 34 radially outward (toward the arrow A1) of the coupling portion 32 and is inclined radially outward toward one axial side (toward the arrow B1) of the coupling portion 32. The other extensions 36 among the plurality of extensions 36 formed on each insulator 18 have a radial extension 40 and an axial extension 42 .

[0017] The retaining portion 38 is formed to correspond to one of the extending portions 36 formed on each insulator 18. The retaining portion 38 protrudes from the outer periphery of the annular portion 34 radially outward (toward the arrow A1) of the connecting portion 32. The retaining portion 38 is located within a range R of the axial dimension of the connecting portion 32 (specifically, the extending portion 36). The retaining portion 38 is located between the radial extending portion 40 and the inclined portion 44 in the circumferential direction of the connecting portion 32. The radial extending portion 40 is located on one side (the arrow C1 side) of the connecting portion 32 relative to the retaining portion 38 in the circumferential direction, and the inclined portion 44 is located on the other side (the arrow C1 side) of the connecting portion 32 relative to the retaining portion 38 in the circumferential direction.

[0018] A notch 46 is formed in the connecting portion 32 in the periphery of the retaining portion 38, between the annular portion 34 and the axially extending portion 42 of the connecting portion 32. The notch 46 is formed to penetrate the connecting portion 32 in the axial direction. The notch 46 is formed along the removal direction of a mold when the insulator 18 is formed by resin molding.

[0019] The retaining portion 38 is formed in a C-shaped opening when viewed in the axial direction of the connecting portion 32. More specifically, the retaining portion 38 has a pair of side wall portions 48, an opening 50, and a closing portion 52. The pair of side wall portions 48 are formed facing each other in the radial direction of the connecting portion 32. Ends of one side (arrow C1 side) of the pair of side wall portions 48 in the circumferential direction of the connecting portion 32 are connected to each other by the closing portion 52. An opening 50 is formed between ends of the other side (arrow C2 side) of the pair of side wall portions 48 in the circumferential direction of the connecting portion 32. In other words, one side (arrow C1 side) of the retaining portion 38 in the circumferential direction of the connecting portion 32 (arrow C1 side) is closed by the closing portion 52, and the other side (arrow C2 side) of the retaining portion 38 in the circumferential direction of the connecting portion 32 is open by the opening 50.

[0020] Terminal portion 28 is inserted into holding portion 38 through opening 50 and is held by holding portion 38. Holding portion 38 is located on one circumferential side (arrow C1 side) of connecting portion 32 with respect to portion 28A of terminal portion 28 connected to winding portion 26. Therefore, a restoring force due to springback acts on terminal portion 28 on the other circumferential side (arrow C2 side) of connecting portion 32. A central portion 28C between portion 28A of terminal portion 28 connected to winding portion 26 and portion 28B held by holding portion 38 is guided by inclined portion 44.

[0021] The opening 50 opens in the direction in which the terminal portion 28 springs back relative to the terminal portion 28 (the direction of arrow C2), and the closing portion 52 is located in the opposite direction (the direction of arrow C1) from the direction in which the terminal portion 28 springs back relative to the terminal portion 28. A pair of protrusions 54 facing each other in the radial direction of the connecting portion 32 are formed on the pair of side wall portions 48. The pair of protrusions 54 are formed on the end portions on the other side (the direction of arrow C2) of the pair of side wall portions 48 as an example of a position for closing the opening 50. The pair of protrusions 54 support the terminal portion 28 and prevent the terminal portion 28 from coming off the retaining portion 38 due to springback. Note that the protrusions 54 may be formed on only one of the pair of side wall portions 48.

[0022] Next, the operation and effects of this embodiment will be described.

[0023] As described above in detail, in the stator 10 according to this embodiment, the holding portions 38 that hold the terminal portions 28 are formed in the connecting portions 32. This makes it possible to avoid the holding portions 38 being located in the space S (see FIG. 7 ) around which the winding portion 26 is wound, as would be the case if the holding portions 38 were formed in the insulating portion 30. This makes it possible to prevent a decrease in the space factor of the winding portion 26 compared to when the holding portions 38 are formed in the insulating portion 30.

[0024] Furthermore, the retaining portion 38 has an opening 50 that opens relative to the terminal portion 28 in the direction in which the terminal portion 28 springs back, a closing portion 52 that is located in the opposite direction relative to the terminal portion 28 from the direction in which the terminal portion 28 springs back, and a protrusion 54 formed in a position that blocks the opening 50. Therefore, the terminal portion 28 can be inserted into the retaining portion 38 through the opening 50 and held by the retaining portion 38. Furthermore, by supporting the terminal portion 28 with the pair of protrusions 54, it is possible to prevent the terminal portion 28 from coming off the retaining portion 38 due to springback.

[0025] Furthermore, the connecting portion 32 has a plurality of extending portions 36 extending toward each insulating portion 30, and one of the plurality of extending portions 36 has an inclined portion 44 that inclines toward one axial side of the connecting portion 32 as it extends radially outward from the connecting portion 32, and a central portion 28C of the terminal portion 28 between a portion 28A connected to the winding portion 26 and a portion 28B held by the holding portion 38 is guided by the inclined portion 44. Therefore, bending of the terminal portion 28 between the holding portion 38 and the winding portion 26 can be suppressed, and the restoring force due to springback acting on the terminal portion 28 can be weakened. This prevents the terminal portion 28 from coming off the holding portion 38 due to springback.

[0026] Furthermore, the retaining portion 38 is located within the range R of the axial dimension of the connecting portion 32. Therefore, for example, compared to when the retaining portion 38 is located outside the range R of the axial dimension of the connecting portion 32, it is possible to prevent the axial length of the stator 10 from becoming longer.

[0027] Next, a modification of this embodiment will be described.

[0028] 8 shows an enlarged view of a main portion of the stator component 12 according to a first modification. In the first modification, the configuration of the retaining portion 38 is modified as follows from the above embodiment. That is, the retaining portion 38 has an opening 50 that opens in the direction opposite to the direction in which the terminal portion 28 springs back relative to the terminal portion 28 (the direction of arrow C1), a closing portion 52 that is located in the direction in which the terminal portion 28 springs back relative to the terminal portion 28 (the direction of arrow C2), and a pair of protrusions 54 formed in positions that close the opening 50.

[0029] With this configuration, the terminal portion 28 can be inserted into the retaining portion 38 through the opening 50 and held by the retaining portion 38. Furthermore, by supporting the terminal portion 28 with the closure portion 52, the terminal portion 28 can be prevented from coming off the retaining portion 38 due to spring back. Furthermore, by forming the pair of protrusions 54 in positions that block the opening 50, the terminal portion 28 can be prevented from coming off the retaining portion 38 through the opening 50. Note that the protrusions 54 may be formed on only one of the pair of side wall portions 48.

[0030] (Second Modification) Figure 9 shows an enlarged view of a main portion of a stator component 12 according to a second modification. In the second modification, the configuration of the extension portion 36 is modified as follows compared to the above embodiment. Specifically, the extension portion 36 has a wall portion 56. The wall portion 56 extends in the axial and circumferential directions of the connecting portion 32. The wall portion 56 is formed between the insulating portion 30 and the retaining portion 38, and separates the insulating portion 30 from the retaining portion 38.

[0031] With this configuration, the wall portion 56 can prevent the terminal portion 28 from moving toward the insulating portion 30 side.

[0032] (Third Modification) Fig. 10 shows an enlarged view of a main portion of a stator component 12 according to a third modification. In the third modification, the configuration of the extension portion 36 is modified as follows compared to the above embodiment. Specifically, the extension portion 36 has a wall portion 58. The wall portion 58 extends in the axial and circumferential directions of the connecting portion 32. The wall portion 58 extends from the axial extension portion 42 to the other axial side (arrow B2 side) of the connecting portion 32. The wall portion 58 is formed between the insulating portion 30 and the annular portion 34, and separates the insulating portion 30 from the annular portion 34. The retaining portion 38 is formed in a groove shape at the end of the wall portion 58 on the other side (arrow B2 side) in the axial direction of the connecting portion 32.

[0033] With this configuration, the configuration of the holding portion 38 can be simplified compared to the above embodiment.

[0034] (Fourth Modification) Fig. 11 shows an enlarged view of a main portion of a stator component 12 according to a fourth modification. In the fourth modification, the configuration of the extension portion 36 is modified as follows compared to the above embodiment. That is, the extension portion 36 has a radial extension portion 40 and an axial extension portion 42. The retaining portion 38 is formed in a pin shape on the axial extension portion 42. The retaining portion 38 protrudes from the axial extension portion 42 radially outward (toward arrow A1) of the connecting portion 32. The retaining portion 38 is formed in a tapered shape that increases in diameter from the base end side to the tip end side.

[0035] With this configuration, the configuration of the holding portion 38 can be simplified compared to the above embodiment.

[0036] (Fifth Modification) Fig. 12 shows an enlarged view of a main portion of a stator component 12 according to a fifth modification. In the fifth modification, the configuration of the extension portion 36 is modified as follows compared to the above embodiment. Specifically, the extension portion 36 has a radial extension portion 40 and an axial extension portion 42. The extension portion 36 has a pair of retaining portions 38. The pair of retaining portions 38 are formed in a pin shape on the radial extension portion 40. The pair of retaining portions 38 protrude from the axial extension portion 42 to the other axial side (the side of arrow B2) of the connecting portion 32. The winding 16 has a pair of terminal portions 28. One of the pair of terminal portions 28 is a terminal portion at the start of winding, and the other of the pair of terminal portions 28 is a terminal portion at the end of winding.

[0037] With this configuration, the configuration of the holding portion 38 can be simplified compared to the above embodiment. Also, the pair of terminal portions 28 can be held by the pair of holding portions 38.

[0038] Among the above-described multiple modified examples, those that can be combined may be appropriately combined and implemented.

[0039] The above describes one embodiment of the technology of the present disclosure, but the technology of the present disclosure is not limited to the above, and it goes without saying that it can be implemented in various modifications within the scope of the gist of the technology.

[0040] The following are supplementary notes regarding the technology of the present disclosure. (Supplementary Note 1) A stator (10) is constituted by a plurality of stator components (12), each of which comprises: a plurality of core components (14) that constitute an annular yoke (20), each having yoke components (22) divided in the circumferential direction of the yoke and teeth (24) protruding from the yoke components to the radially inward direction of the yoke, a winding (16) having a winding portion (26) wound around the teeth, and an insulator (18) that is attached to the core components and has a plurality of insulating portions (30) that insulate the teeth and the winding portion and a connecting portion (32) that connects the plurality of insulating portions together, and the connecting portion has a holding portion (38) that holds an end portion (28) of the winding. (Supplementary Note 2) The stator according to Supplementary Note 1, wherein the holding portion has an opening (50) that opens in a direction in which the terminal portion springs back relative to the terminal portion, a closing portion (52) located in an opposite direction to the direction in which the terminal portion springs back relative to the terminal portion, and a protrusion (54) formed in a position to close the opening. (Supplementary Note 3) The stator according to Supplementary Note 1, wherein the holding portion has an opening that opens in a direction in which the terminal portion springs back relative to the terminal portion, a closing portion located in the direction in which the terminal portion springs back relative to the terminal portion, and a protrusion formed in a position to close the opening. (Supplementary Note 4) The stator according to Supplementary Note 2 or Supplementary Note 3, wherein the connecting portion has an extending portion (36) extending toward the insulating portion, the extending portion having an inclined portion (44) inclined toward one axial side of the connecting portion toward the radially outer side of the connecting portion, and a central portion (28C) between a portion (28A) of the terminal portion connected to the winding portion and a portion (28B) held by the holding portion is guided by the inclined portion. (Supplementary Note 5) The stator according to any one of Supplementary Note 1 to Supplementary Note 4, wherein a wall portion (56) separating the insulating portion from the holding portion is formed between the insulating portion and the holding portion. (Supplementary Note 6) The stator according to Supplementary Note 1, wherein the connecting portion has an extending portion (36) extending toward the insulating portion, and the holding portion is formed on the extending portion.(Supplementary Note 7) The stator according to Supplementary Note 6, wherein the holding portion is formed in a groove shape. (Supplementary Note 8) The stator according to Supplementary Note 6, wherein the holding portion is formed in a pin shape. (Supplementary Note 9) The stator according to any one of Supplementary Notes 1 to 8, wherein the winding has a pair of terminal portions as the terminal portion, and the connecting portion has a pair of holding portions as the holding portion that hold the pair of terminal portions. (Supplementary Note 10) The stator according to any one of Supplementary Notes 1 to 9, wherein the holding portion is located within a range (R) of an axial dimension of the connecting portion.

Claims

1. A stator (10) comprising a plurality of stator components (12), each of which comprises: a plurality of core components (14) constituting an annular yoke (20), each having yoke components (22) divided in the circumferential direction of the yoke and teeth (24) protruding from the yoke components radially inward of the yoke; a winding (16) having a winding portion (26) wound around the teeth; and an insulator (18) attached to the core components and having a plurality of insulating portions (30) that insulate the teeth and the winding portion and a connecting portion (32) that connects the plurality of insulating portions together, the connecting portion having a holding portion (38) that holds an end portion (28) of the winding.

2. A stator as set forth in claim 1, wherein the retaining portion has an opening (50) that opens in the direction in which the terminal portion springs back relative to the terminal portion, a closing portion (52) that is positioned in the opposite direction to the direction in which the terminal portion springs back relative to the terminal portion, and a protrusion (54) formed in a position that closes the opening.

3. A stator as described in claim 1, wherein the retaining portion has an opening that opens in a direction opposite to the direction in which the terminal portion springs back relative to the terminal portion, a closing portion located in the direction in which the terminal portion springs back relative to the terminal portion, and a protrusion formed in a position that blocks the opening.

4. A stator as set forth in claim 2 or claim 3, wherein the connecting portion has an extending portion (36) extending toward the insulating portion, the extending portion has an inclined portion (44) inclined toward one axial side of the connecting portion toward the radially outer side of the connecting portion, and a central portion (28C) of the terminal portion between a portion (28A) connected to the winding portion and a portion (28B) held by the holding portion is guided by the inclined portion.

5. A stator according to any one of claims 1 to 4, wherein a wall (56) is formed between the insulating portion and the holding portion to separate the insulating portion from the holding portion.

6. A stator according to claim 1, wherein the connecting portion has an extending portion (36) extending toward the insulating portion, and the holding portion is formed on the extending portion.

7. The stator according to claim 6, wherein the holding portion is formed in a groove shape.

8. The stator according to claim 6, wherein the holding portion is formed in a pin shape.

9. A stator according to any one of claims 1 to 8, wherein the winding has a pair of terminal portions as the terminal portions, and the connecting portion has a pair of holding portions as the holding portion that hold the pair of terminal portions.

10. A stator according to any one of claims 1 to 9, wherein the holding portion is located within a range (R) of the axial dimension of the connecting portion.

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